Net-shaped duct forming apparatus and method

ABSTRACT

A duct-forming apparatus includes an apparatus frame, a forming piston assembly having a cylinder carried by the apparatus frame and a forming piston extendable from the cylinder. A duct-shaping assembly includes a form die having a form die interior and a forming surface provided in the form die interior; a forming assembly having a plurality of expandable forming sections provided in the form die adjacent to the forming surface; and a plurality of piston openings provided in the expandable forming sections, respectively, and adapted to receive the forming piston of the forming piston assembly. A duct-forming method is also disclosed.

TECHNICAL FIELD

The disclosure relates to seal support ducts. More particularly, thedisclosure relates to a net-shaped duct forming apparatus and methodwhich are suitable for forming a net-shaped seal support duct bypressing a pre-formed duct against a forming surface in a form die usingan expanding semi-solid media.

BACKGROUND

Currently, the process which is used to fabricate seal support rings orducts may require multiple operations including emulsion cleaning,deburring, end trimming, bulge forming, laser trimming and etchcleaning. Consequently, the conventional fabrication process mayengender waste of material and manpower as well as ergonomic problemsassociated with the deburring process.

SUMMARY

The disclosure is generally directed to a duct-forming apparatus. Anillustrative embodiment of the duct-forming apparatus includes anapparatus frame, a forming piston assembly having a cylinder carried bythe apparatus frame and a forming piston extendable from the cylinder. Aduct-shaping assembly includes a form die having a form die interior anda forming surface provided in the form die interior; a forming assemblyhaving a plurality of expandable forming sections provided in the formdie adjacent to the forming surface; and a plurality of piston openingsprovided in the expandable forming sections, respectively, and adaptedto receive the forming piston of the forming piston assembly.

The disclosure is generally further directed to a duct-forming method.An illustrative embodiment of the duct-forming method includes providinga form die having an interior forming surface, providing a formingassembly having a plurality of expandable forming sections, providing apre-formed duct, placing the pre-formed duct in the form die, placingthe forming assembly in the pre-formed duct, forming the pre-formed ductby expanding the expandable forming sections against the pre-formed ductand removing the duct from the form die.

BRIEF DESCRIPTION OF THE ILLUSTRATIONS

FIG. 1 is an end view of an illustrative embodiment of the net-shapedduct forming apparatus.

FIG. 2 is a side view, taken along lines 2-2 in FIG. 1, of anillustrative embodiment of the net-shaped duct forming apparatus.

FIG. 3 is a top view, taken along lines 3-3 in FIG. 1, of anillustrative embodiment of the net-shaped duct forming apparatus.

FIG. 4 is a sectional view of a form die, illustrating placement of apre-formed duct into the form die.

FIG. 5 is a sectional view of the form die with the pre-formed ductseated therein, illustrating placement of a forming assembly into theform die.

FIG. 6 is a sectional view, taken along section lines 6-6 in FIG. 2, ofthe form die with the pre-formed duct and forming assembly placedtherein, preparatory to insertion of a piston through the formingassembly.

FIG. 7 is a sectional view, taken along section lines 7-7 in FIG. 10, ofthe form die with the pre-formed duct and forming assembly placedtherein, illustrating insertion of the piston through the formingassembly and outward expansion of the forming assembly against thepre-formed duct to shape the pre-formed duct into a formed duct.

FIG. 8 is a side view of the formed duct, removed from the form die.

FIGS. 9-11 are side views, respectively, of an illustrative embodimentof the net-forming apparatus, illustrating sequential operation of theduct-forming apparatus.

FIG. 12 is a flow diagram which illustrates an illustrative embodimentof the net-shaped duct forming method.

FIG. 12A is a flow diagram which illustrates an illustrative embodimentof a method for sequentially forming multiple net-shaped ducts.

FIG. 12B is a block diagram of an illustrative embodiment of thenet-shaped duct forming apparatus.

FIG. 13 is a flow diagram of an aircraft production and servicemethodology.

FIG. 14 is a block diagram of an aircraft.

DETAILED DESCRIPTION

Referring initially to FIGS. 1-3 and 9-11, an illustrative embodiment ofa net-shaped duct forming apparatus, hereinafter duct-forming apparatus,is generally indicated by reference numeral 1. The duct-formingapparatus 1 may include a support frame 2 (shown in phantom). Anapparatus frame 6 may be provided on the support frame 2. The apparatusframe 6 may include, for example, an apparatus frame base 7 which may besupported by the support frame 2. Multiple vertical frame members 8 mayextend upwardly from the apparatus frame base 7. Horizontal framemembers 9 may extend between the vertical frame members 8. The verticalframe members 8 and horizontal frame members 9 may define a frameinterior 12.

A forming piston assembly 16 may be provided on the apparatus frame 6.The forming piston assembly 16 may include a cylinder 17, which may behydraulic, and a forming piston 18 which is selectively extendable fromand retractable into the cylinder 17. As shown in FIGS. 1 and 2, theforming piston 18 may be extendable from the cylinder 17 into the frameinterior 12 of the apparatus frame 6 for purposes which will behereinafter described.

A generally horizontal traversing apparatus 22 may extend through theframe interior 12 of the apparatus frame 6. The traversing apparatus 22may include, for example, a generally elongated platform base 23; a pairof spaced-apart platform rails 24 (FIG. 1) provided on the platform base23; and a generally elongated, rectangular support platform 25 whichslidably engages the platform rails 24. Accordingly, as shown in FIGS.9-11, the support platform 25 may be adapted for bidirectionaldisplacement on the platform rails 24 for purposes which will behereinafter described. In application of the duct-forming apparatus 1,which will be hereinafter described, one or multiple duct-shapingassemblies 28 a-28 c, each of which contains a pre-formed duct 36 (FIG.4), may be placed on the support platform 25 of the traversing apparatus22. The support platform 25 may transport the duct-shaping assembly orassemblies 28 through the frame interior 12 of the apparatus frame 6 tofacilitate fabrication of a formed duct 36 a (FIG. 8) from thepre-formed duct 36 (FIG. 4) by operation of the forming piston assembly16. The pre-formed duct 36 may be titanium, or any other suitable metal.

Referring next to FIGS. 4-7 of the drawings, each duct-shaping assembly28 (FIGS. 5-7) may include a form die 30 which may have a pair ofcomplementary mating form die sections 31 (one of which is shown). Theform die 30 has a form die interior 32. A forming surface 33 in theinterior surface of the form die interior 32 has a configuration whichis complementary to that of the desired shape of the formed duct 36 a.As shown in FIGS. 4 and 5, the form die interior 32 of the form die 30is sized and configured to receive and seat the pre-formed duct 36preparatory to formation of the formed duct 36 a, as will be hereinafterdescribed.

Each duct-shaping assembly 28 may include a forming assembly 40 which isseated in the form die interior 32 of the form die 30 and extendsthrough the pre-formed duct 36, as shown in FIGS. 5 and 6. Each formingassembly 40 may include a bottom assembly plate 41, a top assembly plate42 which is spaced-apart from the bottom assembly plate 41 and multipleexpandable forming sections 43 which are sandwiched between the bottomassembly plate 41 and the top assembly plate 42. A piston guide collar42 a may be provided on the top assembly plate 42. Each of the formingsections 43 may be an expandable semi-solid medium such as polyurethane,or any other engineered elastomer. The forming sections 43 of theforming assembly 40 may vary from each other in hardness. Pistonopenings 44 (shown in phantom) may extend centrally through therespective expandable forming sections 43 and may register with thepiston guide collar 42 a on the top assembly plate 42. In operation ofthe net-forming apparatus 1, which will be hereinafter described, theforming piston 18 (FIGS. 1-3) of the forming piston assembly 16 isextended through the piston openings 44 of the forming sections 43. Thediameter of the forming piston 18 may be greater than the diameter ofeach the piston openings 44. Accordingly, as it is extended through thepiston openings 44, as shown in FIG. 7, the forming piston 18 causes theforming sections 43 to expand outwardly against the pre-formed duct 36.Consequently, the forming sections 43 push the pre-formed duct 36against the interior forming surface 33 of the form die 30 and thepre-formed duct 36 conforms to the contour of the forming surface 33,forming the formed duct 36 a (FIG. 8).

Referring next to FIGS. 4-11, in typical operation of the duct-formingapparatus 1, a first duct-shaping assembly 28 a may initially beassembled and placed on the support platform 25 of the traversingapparatus 22, as shown in FIG. 9. Accordingly, a form die 30 (FIG. 4)may initially be placed on the support platform 25. As shown in FIG. 4,a generally cylindrical pre-formed duct 36 may then be seated in theform die interior 32 of the form die 30. A forming assembly 40 may thenbe seated in the form die interior 32 of the form die 30 and extendthrough the pre-formed duct 36, as shown in FIG. 6, to complete thefirst duct-shaping assembly 28 a (FIG. 9).

As shown in FIG. 10, the support platform 25 may be moved along theplatform base 23 of the traversing apparatus 22 to position the firstduct-shaping assembly 28 a in alignment with the forming piston 18 ofthe forming piston assembly 16. Simultaneously, a second duct-shapingassembly 28 b may be placed on the support platform 25 in generallyadjacent relationship to the first duct-shaping assembly 28 a. Next, asfurther shown in FIG. 10, the forming piston 18 may be extended from thecylinder 17 of the forming piston assembly 16 and through the pistonguide collar 42 a on the top plate 42 of the forming assembly 40. Asshown in FIGS. 6 and 7, the forming piston 18 is extended through thecentral piston openings 44 in the respective expandable forming sections43 of the forming assembly 40. Accordingly, as it is extended throughthe piston openings 44, as shown in FIG. 7, the forming piston 18 pushesoutwardly against the forming sections 43 and causes the formingsections 43 to expand outwardly against the pre-formed duct 36.Consequently, the pre-formed duct 36 is pushed against the interiorforming surface 33 of the form die 30 and conforms to the contour of theforming surface 33, forming the formed duct 36 a (FIG. 8) . In someapplications, the expandable forming sections 43 of the forming assembly40 may differ from each other in hardness. This may facilitate controlover localized deformation of the walls of the pre-formed duct 36,providing a substantially defect-free formed duct 36 a having homogenouswall thickness. Furthermore, the formed duct 36 a may not requireadditional manufacturing finishing steps such as trim and deburring, forexample.

The forming piston 18 is retracted back into the cylinder 17 of theforming piston assembly 16 and is therefore removed from the pistonopenings 44 of the expandable forming sections 43. As shown in FIG. 11,the support platform 25 may be moved along the platform base 23 untilthe first duct-shaping assembly 28 a is located in an unloading position48 for unloading of the first duct-shaping assembly 28 a from thetraversing apparatus 22. Simultaneously, the second duct-shapingassembly 28 b is located in the frame interior 12 (FIG. 9) of theapparatus frame 6 to receive the forming piston 18 and form a secondformed duct 36 a in the second duct-shaping assembly 28 b by operationof the forming piston assembly 16, as shown in FIG. 11. The firstduct-shaping assembly 28 a (FIGS. 9-11) is disassembled by removing theforming assembly 40 and the formed duct 36 a from the form die 30. Asshown in FIG. 11, a third duct-shaping assembly 28 c may be placed onthe support platform 25 preparatory to formation of a third formed duct36 a in the third duct-shaping assembly 28 c. Accordingly, as thesupport platform 25 moves on the platform base 23 to the right asindicated by the arrow 50 in FIG. 11, the second duct-shaping assembly28 b is moved to the unloading position 48 whereas the thirdduct-shaping assembly 28 c is moved into the frame interior 12 of theapparatus frame 6 for fabrication of a third formed duct 36 a.

Referring next to FIG. 12, a flow diagram 1200 which illustrates anillustrative embodiment of a duct-forming method is shown. In block1202, a form die having an interior forming surface is provided. Inblock 1204, a forming assembly having expandable forming sections ofsemi-solid forming medium is provided. In block 1206, a pre-formed ductis provided. In block 1208, a piston is provided. In block 1210, thepre-formed duct is placed in the form die. In block 1212, the formingassembly is placed in the pre-formed duct. In block 1214, the formingsections of the forming assembly are expanded against the pre-formedduct by extending the piston through the forming assembly. In block1216, the formed duct is removed from the form die.

Referring next to FIG. 12A, a flow diagram 1200 a which illustrates anillustrative embodiment of a method for sequentially forming multiplenet-shaped ducts is shown. In block 1202 a, multiple form dies eachhaving an interior forming surface are provided. In block 1204 a,multiple forming assemblies each having an expandable forming section ofa semi-solid forming medium are provided. In block 1206 a, multiplepre-formed ducts are provided. In block 1208 a, a piston is provided. Inblock 1210 a, the pre-formed ducts are sequentially placed in therespective form dies. In block 1212 a, the forming assemblies aresequentially placed in the respective pre-formed ducts. In block 1214 a,the forming sections of the forming assemblies are sequentially expandedagainst the respective pre-formed ducts by sequentially extending thepiston through the respective forming assemblies. In block 1216 a, theformed ducts are sequentially removed from the respective form dies.

Referring next to FIG. 12B, a block diagram which illustrates anillustrative embodiment of a net-forming apparatus 1 is shown. Thenet-forming apparatus 1 may include a support frame 2 on which isprovided a support platform 25 movable on the support frame 2 in thedirection indicated by the arrow 54. A forming piston 18 may be disposedabove the support platform 25. Duct-shaping assemblies 28 a, 28 b and 28c may be progressively assembled on the support platform 25.Accordingly, a form die 30 may be placed on the support platform 25; aforming assembly 40 may be placed in the form die 30; and a pre-formedduct 36 may be placed in the forming assembly 40 to assemble eachduct-forming assembly 28 a, 28 b and 28 c, as shown with respect to thethird duct-shaping assembly 28 c and indicated by the arrow 52.

A formed duct 36 a may be formed from each pre-formed duct 36 byextending the forming piston 18 into the forming assembly 40 of eachduct-shaping assembly 28 a, 28 b and 28 c, as shown with respect to thesecond duct-shaping assembly 28 b and indicated by the arrow 56, therebyforcing the forming assembly 40 outwardly against the preformed duct 36and the pre-formed duct 36 outwardly against the interior surfaces ofthe form die 30. In the foregoing manner, the duct-shaping assemblies 28a, 28 b and 28 c are progressively moved on the support platform 25beneath the forming piston 18 to form the formed ducts 36 a. When eachduct-shaping assembly 28 a, 28 b and 28 c reaches the unloading position48 on the support platform 25, the forming assembly 40 may be removedfrom the form die 30 and the formed duct 36 a may be removed from theforming assembly 40, as indicated by the arrow 58.

Referring next to FIGS. 13 and 14, embodiments of the disclosure may beused in the context of an aircraft manufacturing and service method 78as shown in FIG. 13 and an aircraft 94 as shown in FIG. 14. Duringpre-production, exemplary method 78 may include specification and design80 of the aircraft 94 and material procurement 82. During production,component and subassembly manufacturing 84 and system integration 86 ofthe aircraft 94 takes place. Thereafter, the aircraft 94 may go throughcertification and delivery 88 in order to be placed in service 90. Whilein service by a customer, the aircraft 94 may be scheduled for routinemaintenance and service 92 (which may also include modification,reconfiguration, refurbishment, and so on).

Each of the processes of method 78 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof vendors, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 14, the aircraft 94 produced by exemplary method 78 mayinclude an airframe 98 with a plurality of systems 96 and an interior100. Examples of high-level systems 96 include one or more of apropulsion system 102, an electrical system 104, a hydraulic system 106,and an environmental system 108. Any number of other systems may beincluded. Although an aerospace example is shown, the principles of theinvention may be applied to other industries, such as the automotiveindustry.

The apparatus embodied herein may be employed during any one or more ofthe stages of the production and service method 78. For example,components or subassemblies corresponding to production process 84 maybe fabricated or manufactured in a manner similar to components orsubassemblies produced while the aircraft 94 is in service. Also, one ormore apparatus embodiments may be utilized during the production stages84 and 86, for example, by substantially expediting assembly of orreducing the cost of an aircraft 94. Similarly, one or more apparatusembodiments may be utilized while the aircraft 94 is in service, forexample and without limitation, to maintenance and service 92.

Although the embodiments of this disclosure have been described withrespect to certain exemplary embodiments, it is to be understood thatthe specific embodiments are for purposes of illustration and notlimitation, as other variations will occur to those of skill in the art.

1. A duct-forming apparatus, comprising: an apparatus frame; a formingpiston assembly having a cylinder carried by said apparatus frame and aforming piston extendable from said cylinder; and a duct-shapingassembly comprising: a form die having a form die interior and a formingsurface provided in said form die interior; a forming assembly having atleast one expandable forming section provided in said form die adjacentto said forming surface; and at least one piston opening provided insaid at least one expandable forming section, respectively, and adaptedto receive said forming piston of said forming piston assembly.
 2. Theapparatus of claim 1 wherein each of said expandable forming sectionscomprises a semi-solid medium.
 3. The apparatus of claim 1 wherein saidapparatus frame comprises an apparatus frame base, a plurality ofvertical frame members extending from said apparatus frame base and aplurality of horizontal frame members carried by said vertical framemembers, and wherein said cylinder of said forming piston assembly iscarried by said horizontal frame members.
 4. The apparatus of claim 1further comprising a support frame and wherein said apparatus frame iscarried by said support frame.
 5. The apparatus of claim 1 furthercomprising a traversing apparatus extending through said apparatus frameand wherein said duct-shaping assembly is carried by said traversingapparatus.
 6. The apparatus of claim 5 wherein said traversing apparatuscomprises a platform base and a support platform carried by saidplatform base, and wherein said duct-shaping assembly is carried by saidsupport platform.
 7. The apparatus of claim 6 further comprising atleast one platform rail carried by said platform base and wherein saidsupport platform slidably engages said platform rail.
 8. The apparatusof claim 1 wherein said expandable forming sections of said formingassembly vary in hardness.
 9. A duct-forming apparatus, comprising: anapparatus frame having a frame interior; a forming piston assemblyhaving a cylinder carried by said apparatus frame and a forming pistonextendable from said cylinder into said frame interior; and aduct-shaping assembly provided in said frame interior of said apparatusframe and comprising: a form die having a form die interior and aforming surface provided in said form die interior; a forming assemblyhaving a plurality of expandable forming sections provided in said formdie adjacent to said forming surface; and a plurality of piston openingsprovided in said expandable forming sections, respectively, and adaptedto receive said forming piston of said forming piston assembly.
 10. Theapparatus of claim 9 wherein each of said expandable forming sectionscomprises a semi-solid medium.
 11. The apparatus of claim 9 wherein saidapparatus frame comprises an apparatus frame base, a plurality ofvertical frame members extending from said apparatus frame base and aplurality of horizontal frame members carried by said vertical framemembers, and wherein said cylinder of said forming piston assembly iscarried by said horizontal frame members.
 12. The apparatus of claim 9further comprising a support frame and wherein said apparatus frame iscarried by said support frame.
 13. The apparatus of claim 9 furthercomprising a traversing apparatus extending through said frame interiorof said apparatus frame and wherein said duct-shaping assembly iscarried by said traversing apparatus.
 14. The apparatus of claim 13wherein said traversing apparatus comprises a platform base and asupport platform carried by said platform base, and wherein saidduct-shaping assembly is carried by said support platform.
 15. Theapparatus of claim 14 further comprising at least one platform railcarried by said platform base and wherein said support platform slidablyengages said platform rail.
 16. The apparatus of claim 9 wherein saidexpandable forming sections of said forming assembly vary in hardness.17. A duct-forming method, comprising: providing a form die having aninterior forming surface; providing a forming assembly having aplurality of expandable forming sections; providing a pre-formed duct;placing said pre-formed duct in said form die; placing said formingassembly in said pre-formed duct; forming said pre-formed duct byexpanding said expandable forming sections against said pre-formed duct;and removing said duct from said form die.
 18. The method of claim 17wherein said expanding said expandable forming sections against saidpre-formed duct comprises providing a piston and extending said pistonthrough said expandable forming sections.
 19. The method of claim 17wherein said providing a forming assembly having a plurality ofexpandable forming sections comprises providing a forming assemblyhaving a plurality of expandable forming sections comprising asemi-solid medium.
 20. The method of claim 17 wherein said providing aforming assembly having a plurality of expandable forming sectionscomprises providing a forming assembly having a plurality of expandableforming sections differing in hardness.
 21. A duct-forming apparatus foran aircraft part, comprising: a support frame; an apparatus frame havinga frame base, a plurality of spaced-apart vertical frame membersextending from said frame base, a plurality of horizontal frame memberscarried by said vertical frame members and a frame interior defined bysaid frame base, said vertical frame members and said horizontal framemembers; a traversing platform having a generally elongated platformbase extending through said frame interior of said apparatus frame and asupport platform slidably carried by said platform base; a formingpiston assembly having a cylinder carried by said horizontal framemembers of said apparatus frame and a forming piston extendable fromsaid cylinder into said frame interior; and a duct-shaping assemblyprovided in said frame interior of said apparatus frame and comprising:a generally cylindrical form die having a form die interior and aforming surface provided in said form die interior; a forming assemblyhaving a plurality of expandable forming sections provided in said formdie adjacent to said forming surface; and a plurality of piston openingsprovided in said expandable forming sections, respectively, and adaptedto receive said forming piston of said forming piston assembly.
 22. Aduct-forming method for an aircraft part, comprising: providing a formdie having an interior forming surface; providing a forming assemblyhaving a plurality of expandable forming sections comprising asemi-solid medium and a plurality of piston openings extending throughsaid expandable forming sections, respectively; providing a generallycylindrical pre-formed duct; placing said pre-formed duct in said formdie; placing said forming assembly in said pre-formed duct; forming saidpre-formed duct by providing a piston, extending said piston throughsaid piston openings of said expandable forming sections and expandingsaid expandable forming sections against said pre-formed duct; andremoving said duct from said form die.